3D Technologies Help Custom Prosthetics Hit Their Stride

PTC's Creo 3D design suite was critical to the iPec development effort. The software was instrumental for everything from formalizing the layout for the printed circuit board packaging to creating the organic shapes for the design, even down to employing FEA capabilities to explore the structural integrity of the device, Leydet told us.

Beyond 3D design tools, 3D printers are also making a mark on prosthetic design, among other medical applications. Most recently, there's the story of Emma Lavelle, a child born with arthrogryposis multiplex congenital (AMC), a non-progressive condition that causes still joints and underdeveloped muscles.

As Emma grew, her parents were determined to find her a way to play and interact like other kids her age, but she couldn't lift her arms. Her parents came across the Wilmington Robotic Exoskeleton (WREX), an assistive device made out of hinged bars and resistance bands, and hooked up with the researchers and doctors from Nemours/Alfred I. duPoint Hospital for Children in Wilmington, Del., to modify the device to meet the needs of the two-year-old, 25-pound Emma -- who was much smaller than most patients and not tied to a wheelchair.

The design challenge in this case was one of scalability. The research team determined that its traditional CNC method of producing the WREX wouldn't work for Emma's version because of the small size and detail required. Alternatively, the team turned to a Stratasys Dimension 3D printer to construct a lightweight WREX, custom fit for Emma in ABS plastic, and able to be affixed to a small plastic vest.

Since being outfitted with her custom WREX prosthetic, what Emma affectionately calls her "magic arms," she has been able to play with toys, feed herself, and hug her family, just like other kids. For the research and medical team evolving the WREX, 3D printing and 3D CAD tools enable them to continually improve upon the device and make modifications as Emma and now an expanded contingent of other small patients grow in size.

"This is one of those industries that matches perfectly with 3D printing and additive manufacturing because we need custom everything," said Whitney Sample, one of the research design engineers who built Emma's WREX, in a video explaining the project. Sample and his team see 3D printing and 3D scanning as the future for custom prosthetics. "The ABS plastic is strong and durable enough to handle the abuse, and we can answer a need in a heartbeat," he said.

Beth, this is a great story. With the advancement of electronics and design software, the missing piece was manufacturing. As another great example of the power of 3D printed objects this is very encouraging. After all, if you can make a receiver for a gun with 3D, you should be able to make good prosthetics.

Love that last point, Naperlou. Absolutely, 3D printing is advancing to cover all ends of the spectrum in terms of manufacturing. In terms of medical technologies, it's really had an impact even beyond the manufacture of custom prosthetics. Check out our slide show on 3D printing in the medical sector.

Yes, I also agree. An inspiring story about Emma that really drives home the point on how technology breakthroughs can have such a positive impact on people's lives. Since the cost of 3D printing has come down so much, I imagine that new arms could also be printed again should the current ones wear out or become damaged.

What a wonderful story. If Oscar Pistorius' performance in the Olympics taught us anything, it's that prosthetic limbs needn't be a handicap. I really do believe that technology will eliminate all disabilities by the end of this century.

It's great to see these types of advances taking place. Just in the same way that high performance cars eventually see their developments embodied in the consumer versions - I hope that these techniques eventually become available to the average consumer. What a boon to veterans, the disabled and the aging.

Rob: Magic arms is actually just a pet name she gave to the prosthetic device that helps her now have control over her arms to do everyday things like play and feed herself. It is more of a term of endearment to show her enthusiasm for new mobility.

@Greg: That's actually a point I didn't spend time on in the post, but a real lifesaver for Emma's parents. There is obviously wear and tear on the device, particularly as Emma gains in mobility. With the 3D printing approach, her parents can simply contact the research/medical team and explain what part is broken (take a picture if need be) and a replacement can be easily and cheaply produced. Minimal downtime, which is a great thing for Emma.

With prices on 3D printers coming down and with materials and other related technologies vastly improving, I do think capabilities like these will become easier and more accessible to mainstream medical practices, aiding in their adoption.

I can see that it would be great to work in this field. I have a 4 year old grandson born without one arm - not even a shoulder. I have wondered if it would be possible to fit him with a wrap-around vest that a prosthetic arm could be attached to. The hand on his one arm has only a thumb and two stubby half fingers. This handicap is apparently due to his arm and hand being pinched off during development by the amniotic membrane. He is a very happy child who doesn't yet recognize he is so different from others and he naturally uses his feet when one hand can't complete a task. He may never need a prosthetic to get through life, but it would be something worth checking into.

Virtual Reality (VR) headsets are getting ready to explode onto the market and it appears all the heavy tech companies are trying to out-develop one another with better features than their competition. Fledgling start-up Vrvana has joined the fray.

A Tokyo company, Miraisens Inc., has unveiled a device that allows users to move virtual 3D objects around and "feel" them via a vibration sensor. The device has many applications within the gaming, medical, and 3D-printing industries.

While every company might have their own solution for PLM, Aras Innovator 10 intends to make PLM easier for all company sizes through its customization. The program is also not resource intensive, which allows it to be appropriated for any use. Some have even linked it to the Raspberry Pi.

solidThinking updated its Inspire program with a multitude of features to expedite the conception and prototype process. The latest version lets users blend design with engineering and manufacturing constraints to produce the cheapest, most efficient design before production.

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